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At least 91 records · Page 5

Impact Damage and Strain Rate Effects for Toughened Epoxy Composite Structures

Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.

Chamis, Christos C.↗

Investigation of the fracture mechanics of boride composites

Significant results were obtained in fabrication studies of the role of metallic additives of Zr, Ti, Ni, Fe and Cr on the densification of ZrB2. All elemental additions lower the processing temperatures required to effect full densification of ZrB2. Each addition effects enhanced densification by a clearly distinguishable and different mechanism and the resulting fabricated materials are different. A significant improvement in strength and fracture toughness was obtained for the ZrB2/Ti composition. Mechanical characterization studies for the ZrB2/SiC/C composites and the new ZrB2/Metal materials produced data relevant to the effect of impacting load on measured impact energies, a specimen configuration for which controlled fracture could occur in a suitably hard testing apparatus, and fracture strength data. Controlled fracture--indicative of measurable fracture toughness--was obtained for the ZrB2-SiC-C composite, and a ZrB2/Ti composite fabricated from ZrB2 with an addition of 30 weight per cent Ti. The increased strength and toughness of the ZrB2/Ti composite is consistent with the presence of a significantly large amount of a fine grained acicular phase formed by reaction of Ti with ZrB2 during processing.

Clougherty, E. V.↗

Coupling system for reducing fatigue and dynamic amplification of loads in objects

A coupling system can include an energy transfer device and a load mitigation system. The energy transfer device can include a shaft, gear, chain or piston-cylinder arrangement to transfer the energy from a power supply to an object to be moved. The load mitigation system can be used to limit or prevent the transfer of forces from the object to the drive unit as a result of external loads being applied to the object. The load mitigation system can be pre-loaded such that external loads on the object having an excessive impulsive or resonant cyclic force greater than the pre-load force on the load mitigation system are reduced and only partially transferred to the energy transfer device and power supply. The load mitigation system can dampen both resonant loads and impulsive impact loads occurring at the object thereby preventing damage and extending life.

Blackmon, James B.↗

Coupling system for reducing fatigue and dynamic amplification of loads in objects

A coupling system can include an energy transfer device and a load mitigation system. The energy transfer device can include a shaft, gear, chain or piston-cylinder arrangement to transfer the energy from a power supply to an object to be moved. The load mitigation system can be used to limit or prevent the transfer of forces from the object to the drive unit as a result of external loads being applied to the object. The load mitigation system can be pre-loaded such that external loads on the object having an excessive impulsive or resonant cyclic force greater than the pre-load force on the load mitigation system are reduced and only partially transferred to the energy transfer device and power supply. The load mitigation system can dampen both resonant loads and impulsive impact loads occurring at the object thereby preventing damage and extending life.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Simulation of Dynamic Crushing Behavior of Simulated Carbon/Epoxy Stanchions Using MAT58 and MAT213 in LS-DYNA

Carbon fiber-reinforced polymer (CFRP) composites have shown promise as a material for structures designed to absorb energy in crush-style impact loading. In complementing the lightweight and tailorable characteristics of CFRP structures, the benefits of impact energy absorption are particularly interesting in aerospace vehicles that require excellent crashworthiness performance. However, simulating the behavior of CFRP structures in dynamic, crushing-style impact loading is challenging because of the many damage and failure modes that are essential to capture in the model. For the present investigation, CFRP stanchions were tested using a crash sled experimental test rig. The stanchions were designed by the Composite Materials Handbook-17 (CMH-17) Crashworthiness Working Group for the purpose of comparing experimental crash sled tests to corresponding simulations of the tests. The stanchions are C-channel shaped and represent a geometry common in the interior of aerospace vehicle structures. Explicit simulations in LSDYNA were performed using a well-established composite material model (MAT58) and a next-generation material model (MAT213). Fully integrated shell elements were utilized instead of 3D solid elements to limit computation time. In all models, each of the sixteen plies were represented with individual layers of shell elements with tiebreak contact between each adjacent ply pair to simulate interlaminar fracture. Simulating the crushing of the stanchions occurred in two phases. First, the material models were calibrated using flat specimens that were manufactured with the same layup as the stanchions. While the original goal was calibration of material-related properties, meshdependent behavior was observed in simulations with either material model, and an unstructured mesh was selected to remediate undesirable mesh-dependent failure modes. Additionally, for both the MAT58 and MAT213 models, it was found that either the crush force or the failure mode could be modeled accurately, but no set of parameters could be identified to attain both results in the same model. Once satisfactory calibration was achieved, the same material parameters were applied to the stanchion crush simulations. The stanchion simulations showed that MAT213 more accurately predicted the experimentally determined crush force, and both material models predicted key aspects of the experimentally observed failure modes.

Composite Materials↗

Mitigation of spall fracture by evolving porosity

Ductile materials subject to impact loading conditions can undergo spall fracture when an incoming compressive stress wave reflects off interfaces and free surfaces as a tensile stress wave. Experimental observations suggest that in ductile materials, spall fracture is driven by the evolution of porosity. However, the presence of initial porosity in ductile materials also introduces plastic compressibility, which can attenuate the incoming compressive stress wave and, as a result, reduce the amplitude of the reflected tensile stress wave. This, in turn, can mitigate or delay spall fracture. In this work, we report on finite deformation finite element calculations that analyze the response of porous ductile materials subjected to impact loading conditions. Two sets of calculations are carried out, in the first set the material contains initial porosity values ranging from 0% to 5% while in the second set the material also undergoes stress-controlled porosity nucleation. Both sets of calculations are carried out for a wide range of imposed impact velocities. Here, our results show that porosity in ductile materials can, under certain circumstances, mitigate spall fracture by attenuating stress waves. Results correlating the effects of impact velocity, initial porosity, and porosity nucleation on spall fracture are presented and the underlying mechanisms are discussed.

36 MATERIALS SCIENCE↗

A comparative study between experimental results and numerical predictions of multi-wall structural response to hypervelocity impact

Over the last three decades, multiwall structures have been analyzed extensively, primarily through experiment, as a means of increasing the protection afforded to spacecraft structure. However, as structural configurations become more varied, the number of tests required to characterize their response increases dramatically. As an alternative, numerical modeling of high-speed impact phenomena is often being used to predict the response of a variety of structural systems under impact loading conditions. This paper presents the results of a preliminary numerical/experimental investigation of the hypervelocity impact response of multiwall structures. The results of experimental high-speed impact tests are compared against the predictions of the HULL hydrodynamic computer code. It is shown that the hypervelocity impact response characteristics of a specific system cannot be accurately predicted from a limited number of HULL code impact simulations. However, if a wide range of impact loadings conditions are considered, then the ballistic limit curve of the system based on the entire series of numerical simulations can be used as a relatively accurate indication of actual system response.

Schonberg, William P.↗

Analysis of delamination in cross ply laminates initiating from impact induced matrix cracking

Several two dimensional finite element analyses of (0 sub 2/90 sub 8/0 sub 2) glass/epoxy and graphite-epoxy composite laminates were performed to study some of the characteristics of damage development due to an impact load. A cross section through the thickness of the laminate with fixed ends, and carrying a transverse load in the center was analyzed. Inclined matrix cracks such as those produced by low velocity impact were modeled in the 90 deg ply group. The introduction of the matrix cracks caused large interlaminar tension and shear stresses in the vicinity of both crack tips in the 0/90 and 90/0 interfaces. The large interlaminar stresses at the ends of the matrix cracks indicate that matrix cracking may give rise to delamination. The ratio of mode I to total strain energy release rate at the beginning of delamination calculated at the two matrix crack tips was 60 and 28 pct., respectively, in the glass/epoxy laminate. The corresponding ratio was 97 and 77 pct. in the graphite-epoxy laminate. Thus, a significant mode I component of strain energy release rate may be present at the delamination initiation due to an impact load.

Salpekar, S. A.↗

A Novel Design of Guiding Stress Wave Propagation

Impact loads can induce a series of undesirable physical phenomena including vibration, acoustical shock, perforation, fracture and fragmentation, etc. The energy associated with the impact loads can lead to severe structure damage and human injuries. A design approach which effectively reduces these negative impacts through shock/stress wave diversion is highly needed. In this paper, a computational model which predicts stress wave propagation by considering different beam geometries and configurations is developed. Additionally, a novel concept of wave guide design which modifies the stress wave propagation path without disturbance is also presented. Furthermore, this design approach is not only useful for material property characterization particularly at intermediate or high strain rates, but also allows stress wave propagation in a desired direction as the shock/impact energy can be redistributed in controllable paths. The numerical results are experimentally verified through a Drop-Hopkinson bar apparatus at Sandia National Laboratories.

36 MATERIALS SCIENCE↗

Analysis of delamination in cross-ply laminates initiating from impact induced matrix cracking

Two-dimensional finite element analyses of (02/90(8)/02) glass/epoxy and graphite/epoxy composite laminates were performed to investigate some of the characteristics of damage development due to an impact load. A cross section through the thickness of the laminate with fixed ends, and carrying a transverse load in the center, was analyzed. Inclined matrix cracks, such as those produced by a low-velocity impact, were modeled in the 90 deg ply group. The introduction of the matrix cracks caused large interlaminar tensile and shear stresses in the vicinity of both crack tips in the 0/90 and 90/0 interfaces, indicating that matrix cracking may give rise to delamination. The ratio of Mode I to total strain energy release rate, G(I)/G(total), at the beginning of delamination, calculated at the two (top and bottom) matrix crack tips was 60 and 28 percent, respectively, in the glass/epoxy laminate. The corresponding ratio was 97 and 77 percent in the graphite/epoxy laminate. Thus, a significant Mode I component of strain energy release rate may be present at the delamination initiation due to an impact load. The value of strain energy release rate at either crack tip increased due to an increase in the delamination length at the other crack tip and may give rise to an unstable delamination growth under constant load.

Salpekar, S. A.↗

Full-Scale Passive Earth Entry Vehicle Landing Tests: Methods and Measurements

During the summer of 2016, a series of drop tests were conducted on two passive earth entry vehicle (EEV) test articles at the Utah Test and Training Range (UTTR). The tests were conducted to evaluate the structural integrity of a realistic EEV vehicle under anticipated landing loads. The test vehicles were lifted to an altitude of approximately 400m via a helicopter and released via release hook into a predesignated 61 m landing zone. Onboard accelerometers were capable of measuring vehicle free flight and impact loads. High-speed cameras on the ground tracked the free-falling vehicles and data was used to calculate critical impact parameters during the final seconds of flight. Additional sets of high definition and ultra-high definition cameras were able to supplement the high-speed data by capturing the release and free flight of the test articles. Three tests were successfully completed and showed that the passive vehicle design was able to withstand the impact loads from nominal and off-nominal impacts at landing velocities of approximately 29 m/s. Two out of three test resulted in off-nominal impacts due to a combination of high winds at altitude and the method used to suspend the vehicle from the helicopter. Both the video and acceleration data captured is examined and discussed. Finally, recommendations for improved release and instrumentation methods are presented.

Littell, Justin D.↗

Energy-Absorbing, Lightweight Wheels

Improved energy-absorbing wheels are under development for use on special-purpose vehicles that must traverse rough terrain under conditions (e.g., extreme cold) in which rubber pneumatic tires would fail. The designs of these wheels differ from those of prior non-pneumatic energy-absorbing wheels in ways that result in lighter weights and more effective reduction of stresses generated by ground/wheel contact forces. These wheels could be made of metals and/or composite materials to withstand the expected extreme operating conditions. As shown in the figure, a wheel according to this concept would include an isogrid tire connected to a hub via spring rods. The isogrid tire would be a stiff, lightweight structure typically made of aluminum. The isogrid aspect of the structure would both impart stiffness and act as a traction surface. The hub would be a thin-walled body of revolution having a simple or compound conical or other shape chosen for structural efficiency. The spring rods would absorb energy and partially isolate the hub and the supported vehicle from impact loads. The general spring-rod configuration shown in the figure was chosen because it would distribute contact and impact loads nearly evenly around the periphery of the hub, thereby helping to protect the hub against damage that would otherwise be caused by large loads concentrated onto small portions of the hub.

Waydo, Peter↗

NASA experiments onboard the controlled impact demonstration

The structural crashworthiness tests conducted by NASA on the December 1, 1984 controlled impact demonstration are discussed. The components and locations of the data acquisition and photographic systems developed by NASA to evaluate impact loads throughout the aircraft structure and the transmission of loads into the dummies are described. The effectiveness of the NASA designed absorbing seats and the vertical, longitudinal, and transverse impact loads are measured. Data that is extremely applicable to crash dynamics structural research was obtained by the data acquisition system and very low load levels were measured for the NASA energy absorbing seats.

Hayduk, R. J.↗

Experimental and Analytical Characterization of the Macromechanical Response for Triaxial Braided Composite Materials

Increasingly, carbon composite structures are being used in aerospace applications. Their highstrength, high-stiffness, and low-weight properties make them good candidates for replacing many aerospace structures currently made of aluminum or steel. Recently, many of the aircraft engine manufacturers have developed new commercial jet engines that will use composite fan cases. Instead of using traditional composite layup techniques, these new fan cases will use a triaxially braided pattern, which improves case performance. The impact characteristics of composite materials for jet engine fan case applications have been an important research topic because Federal regulations require that an engine case be able to contain a blade and blade fragments during an engine blade-out event. Once the impact characteristics of these triaxial braided materials become known, computer models can be developed to simulate a jet engine blade-out event, thus reducing cost and time in the development of these composite jet engine cases. The two main problems that have arisen in this area of research are that the properties for these materials have not been fully determined and computationally efficient computer models, which incorporate much of the microscale deformation and failure mechanisms, are not available. The research reported herein addresses some of the deficiencies present in previous research regarding these triaxial braided composite materials. The current research develops new techniques to accurately quantify the material properties of the triaxial braided composite materials. New test methods are developed for the polymer resin composite constituent and representative composite coupons. These methods expand previous research by using novel specimen designs along with using a noncontact measuring system that is also capable of identifying and quantifying many of the microscale failure mechanisms present in the materials. Finally, using the data gathered, a new hybrid micromacromechanical computer model is created to simulate the behavior of these composite material systems under static and ballistic impact loading using the test data acquired. The model also quantifies the way in which the fiber/matrix interface affects material response under static and impact loading. The results show that the test methods are capable of accurately quantifying the polymer resin under a variety of strain rates and temperature for three loading conditions. The resin strength and stiffness data show a clear rate and temperature dependence. The data also show the hydrostatic stress effects and hysteresis, all of which can be used by researchers developing composite constitutive models for the resins. The results for the composite data reveal noticeable differences in strength, failure strain, and stiffness in the different material systems presented. The investigations into the microscale failure mechanisms provide information about the nature of the different material system behaviors. Finally, the developed computer model predicts composite static strength and stiffness to within 10 percent of the gathered test data and also agrees with composite impact data, where available.

Littell, Justin D.↗

Dynamic loading on impact surfaces of a high subsonic elliptic jet

The feedback resonance in a high subsonic velocity range was investigated for the case where a small aspect ratio (2:1) elliptic jet impinged perpendicularly on a flat plate. This resonance was observed for Mach numbers greater than 0.7 for plate locations between 4 and 9 major radii downstream of the exhaust plane. At the predominant resonant conditions, the loading region and sound source terms were found to be concentrated along the major axis direction on the impact surface.

Wat, J. K.↗

Development of GENOA Progressive Failure Parallel Processing Software Systems

A capability consisting of software development and experimental techniques has been developed and is described. The capability is integrated into GENOA-PFA to model polymer matrix composite (PMC) structures. The capability considers the physics and mechanics of composite materials and structure by integration of a hierarchical multilevel macro-scale (lamina, laminate, and structure) and micro scale (fiber, matrix, and interface) simulation analyses. The modeling involves (1) ply layering methodology utilizing FEM elements with through-the-thickness representation, (2) simulation of effects of material defects and conditions (e.g., voids, fiber waviness, and residual stress) on global static and cyclic fatigue strengths, (3) including material nonlinearities (by updating properties periodically) and geometrical nonlinearities (by Lagrangian updating), (4) simulating crack initiation. and growth to failure under static, cyclic, creep, and impact loads. (5) progressive fracture analysis to determine durability and damage tolerance. (6) identifying the percent contribution of various possible composite failure modes involved in critical damage events. and (7) determining sensitivities of failure modes to design parameters (e.g., fiber volume fraction, ply thickness, fiber orientation. and adhesive-bond thickness). GENOA-PFA progressive failure analysis is now ready for use to investigate the effects on structural responses to PMC material degradation from damage induced by static, cyclic (fatigue). creep, and impact loading in 2D/3D PMC structures subjected to hygrothermal environments. Its use will significantly facilitate targeting design parameter changes that will be most effective in reducing the probability of a given failure mode occurring.

Abdi, Frank↗

A Reliable Earth Return System for Safe Recovery of Mars Samples

The objective of a Mars sample return mission is to bring selected Mars surface materials to Earth. Numerous approaches for the Earth-return segment have been analyzed including propulsive or aerocapture return to low-Earth orbit followed by Space Shuttle rendezvous and direct entry. Of these approaches, ballistic entry of a small capsule terminating in a ground landing has been shown to be the lowest risk strategy. Over the past two years, significant work has been performed towards development of a robust direct entry vehicle for Mars sample return. In June 1999, the NASA Planetary Protection Officer provided initial guidance to the former Mars Sample Return Project. The sample return phase of the mission was assigned a restricted Earth return planetary protection classification. The draft mission requirement states that the total mean probability of release of unsterilized Mars material into the Earth;s biosphere must be less than 1.0E-06 (1 in a million). This strict requirement drives the approach and design of the Earth return system. To meet this requirement, selection of the Earth return strategy and development of the Earth return system must be guided by risk, not performance, based decisions. An initial Probabilistic Risk Assessment (PRA) was performed to address the direct entry Earth return system containment assurance reliability and to identify high-risk elements of this system. The results of this PRA identified risk elements that include thermal protection system performance during entry, spin-eject orientation and aerodynamic stability during entry, structural integrity under atmospheric deceleration and impact loads, and tracking/recovery of this system. This initial probabilistic risk quantification demonstrates that, with the proper development program, a prototypical direct entry design can satisfy the containment assurance reliability requirement. Through the current Mars Sample Return Advanced Technology Development effort, an extensive design, analysis, and test program is presently proceeding with the aim of reducing the containment assurance risk of this system. This technology development effort, guided by a continuing PRA, focuses on key risk areas of a direct entry Earth return system including: the thermal protection system, impact dynamics, structural performance, aerodynamic stability, and ground recovery. This development program will culminate in a system validation flight test, 1-2 years prior to launch of the flight system. This flight test would include the launch, entry, and recovery of a full-scale Earth return system, as a scientific validation of the key risk elements to verify nominal design performance. The results of the initial PRA suggested several dominant failure sequences that can be validated in a flight test. These include: demonstrating the thermal protection system reliability and performance during entry, demonstrating the spin-eject orientation and aero-dynamic stability during entry, demonstrating the structural integrity under atmospheric deceleration and impact loads, and demonstrating tracking and recovery of the Earth return system. This single test will directly address over 50% of the total containment assurance risk elements. This presentation will begin by presenting the relative risk of various Earth return strategies. The results of the initial probabilistic risk assessment will be presented followed by a discussion of the development accomplishments and plans for demonstration of a highly reliable direct entry Earth return system.

Braun, R.↗